Fabric-lined box



06f. 1954 H. YAEGER 2,692,696

FABRIC-LINED BOX.

2 Sheefs-Sheet 1 Filed June 3. 1953 I 4 INVENTOR. 4 121 BY Henry Yoeger ATTORN EY Oct. 26, 1954 H. YAEGER 92,696

FABRICTLINED BOX Filed June 3. 1953 2 Sheets-Sheet 2 INVENTOR.

Henry YCI eger ATTORNEY Patented Oct. 26, 1954 UNITED STATES PATENT OFFICE FABRIC-LINED BOX Henry Yaeger, Bayside, N. Y., assignor to U. S. Basket 00., Inc., New York, N. Y., a corporation Application June 3, 1953, Serial No. 359,398

'7 Claims. 1

The invention relates to fabric-lined boxes or baskets, as for instance sewing baskets and to a method of making same. Conventional fabriclined boxes frequently comprise a frame work with an outer cover and an intermediate card board layer between the frame and the fabriclining on the inside of the box. In the production of such boxes a card board blank is first scored on both sides according to the required folding whereupon the fabric lining consisting of several pieces is glued to the card board blank which is folded and inserted into the frame. This method has drawbacks owing to the many manipulations which are necessary and owing also due to the fact that particularly in the inner creases or corners of the box the fabric lining frequently gets loose and does not stick to the card board. The invention aims to avoid the mentioned drawbacks. It essentially consists in that a card board blank for a structure of which some parts are intended to be folded outwards and other parts to be folded inwards is scored only along the lines of the intended outward folds. A piece of fabric somewhat larger than the card board blank is placed on the latter upon that face which is provided with the scores whereupon the rim of the fabric is turned about the edges of the blank and glued to the latter on its non-scored face. Then, the fabric is sewed to the card board with rows of stitches along the intended lines of inner folds. The card board blank with the fabric thereon can now be folded outwardly along the scores and inwardly along the stitching. The stitching serves the dual purpose, on the one hand, of facilitating the bending or folding along predetermined lines and on the other hand of holding the fabric exactly in and to the inner corners of the folded blank.

The method according to the invention is applicable not only to boxes but also to other structures, as for instance to partitions or shelves for use in boxes, trays or the like.

Further objects and details of the invention will be apparent from the description given here inafter and the accompanying drawing illustrating several embodiments thereof by way of example. In the drawing,

Fig. 1 is a top plan view of a card board blank and a portion of the fabric-lining for a box, such as a sewing basket according to the invention,

Fig. 2 is a cross-section along line 2-2 of Fig. 1,

Fig. 3 is a view similar to Fig. 1 with the fabric secured to the blank,

Fig. 4 is a cross-section along line 1-4 of Fig. 3,

Fig. 5 is a perspective view of the sewing basket with the card board and fabric lining of Figs. 1-4 inserted in the basket frame from which the major portion of the outer cover has been removed,

Fig. 6 is a cross-section along line 6-6 of Fig. 5, a tray being inserted in the basket from which the outer cover is removed,

Fig. '7 is a top plan view of the blank of the partitions of the tray of Fig. 6, and

Fig. 8 is a cross-section of a box portion with a rack.

Referring now to the drawing, Figs. 1 to 6, il lustrate a sewing basket which comprises the outer cover of basket weave ID, a frame H, a card board wall structure [2 and a fabric lining l3. A lid which is not shown may be provided. The frame H consists of a bottom plate 14, four corner uprights 15, intermediate uprights IB and a rectangular upper rim formed by two longitudinals I7 and two transverse rods It. At least the members l5, [6, H and [8 are preferably of wood. The card board wall structure is made of a cruciform blank [9 comprising a center portion 20 and four side portions or side panels 2!, 22, 23, 22 of which the opposite panels 2! and 24 extend farther from the center panel than the panels 22 and 23 by twice the distance d which the opposed ledges 3| shown in Figs. 5 and 6 project inside the box. At a short distance from the outer edge I20, each side portion is scored along a line 25 parallel to its outer edge I20. The scores are provided on the face of the blank which is the top face in Fig. l. The short portions 2!, 22', 23', and 24' between the outer edge and the line 25 of each side panel are in tended to form flanges as it will be described hereinafter. The side panels 2| and 24 are provided each with two additional score lines 35 and 36 where the projecting corners of the ledges 3! are to be formed. In a box where no ledges are desired the panels 2| and 24 will project the same distance from the center panel as the panels 22 and 23 and will be provided with scores 25. A rectangular piece of fabric 26, which is some what larger in both directions than the spread of the pairs of opposite side portions of the blank I9, is placed on top of the scored face of the blank iii. The rim of the fabric is turned about the outer edges I20 of the side portions and glued to the lower faces of the portions 2 l 22, 23 and 24 as indicated in Figs. 3 and 4 at l2]. It will be noticed that the four corner pieces 21 are free. The fabric 26 will be sewed to the card board blank with a line of stitches 28 between the center portion 20 and each of the side portions 2!, 22, 23 and 24. These stitches serve the purpose not only of securing the fabric to the card board but also of weakening the card board material similarly to the scores 25 in order to facilitate the folding of the blank. Thefabric will also be sewed to the card board along lines of stitches 38 and 39 at the distance d from the score lines 35 and 36. Thereupon the sides 2|, 22,23 and 24 will be turned up along the lines 28, and the panels 2| and 24 will be also folded inward along the lines 38 and 39 and outward along the score lines 35 and 36 whereby the ledges 31 will be formed which as shown in Fig. 6 may be reinforced by wooden transverse members 46 secured to the uprights of the frame II. The portions 2|, 22', 23 and 24' will be turned outward so as to form the aforementioned flanges. Thus, wherever an outer corner is formed, i. e. a fold with the fabric on the convex side of the bend, the card board has been scored, and where an inner corner is formed, i. e. a fold with the fabric on the concave side of the fold, the card board has been perforated by the stitching. Furthermore, it will be noted that the stitching holds the fabric in the inner bottom corners of the open fabriclined box formed by the center panel 26 and the erected side panels 2|, 22, 23 and 24, and also in the inner corners between the side panels 2! and 24 and the ledges 3|, whereas the fabric is stretched over the bends of the outer corners along the lines 25 of the flanges and 35 and 36 of the ledges. The card board box with its fabric lining will then be inserted into the frame i l as clearly shown in Fig. 5. With the parts properly dimensioned the center portion 20 will rest on the bottom plate l4 while the flange portions 2 l 22, 23' and 24 bear on and are secured to the upper rim members I! and [8 of the frame e. g. by nails 29. The free corner portions 21 of the fabric will have been pulled outward when the card board box has been folded. Upon the insertion of the box in the frame, each of these free portions will be tucked into one of the spaces between a corner upright l and an adjacent intermediate upright 16 to be concealed by the outer cover It! which may be in the form of a basket weave or may consist of any other suitable material.

The box or basket according to the invention excels by the fact that the entire lining consists of one piece of fabric without any stitched or glued seams for the connection of parts thereof and that the fabric is tightly secured to the inner corners at the bottom of the box. The method of making the box is advantageous owing to the fact that it requires only a very few steps of operation, considering that the card board blank need be scored on only one face, that the fabric need be glued only with its margin to the flange portions, that it is stretched by the bend of an outer corner and thus tightly held to the cardboard face, and that the stitching not only substitutes for a scoring of the other face of the board but also holds the fabric in the innermost corners of the box.

The same principle of scoring where outer corners are desired and of stitching for inner corners, can be advantageously applied also to other structures or other portions of a box. Thus Fig. 6 shows in cross-section the ledges 3| carrying a tray 32 with fabric lined partitions 33. The tray comprises the bottom 42 and pairs 43 and 44 of opposite side walls. This tray may be of any conventional and suitable material and structure. In order to provide it with the partitions 33 a card board blank 45 of rectangular form is made as shown in Fig. '7. The blank has a pair of shorter sides 46 equal to the inner length of the tray side 43, and a pair of longer sides 41 equal to the inner length of the sides 44 plus twice the height times the number of the partitions 33. The blank is provided with scores 46 parallel to the sides 46. The scores 48 are spaced from one another a distance equal to the desired 4 distance plus twice the height of the partitions. As to the distance of the scores adjacent the sides 46 only once the height of the partition plus its desired distance from the adjacent side 46 has to be figured. A piece of fabric 49 larger than the blank is placed on the scored face of the latter and its projecting margin is turned down to be glued to the opposite face of the blank as indicated at 56. The fabric is then stitched to the card board along lines 5! parallel to the scores 48 and at distances therefrom equal to the desired height of the partitions. Thereupon the blank is folded to form outer corners where the scores are located and inner corners along the lines 5| of the stitching. In this manner the partitions 33' are formed of doubled material and connected by panels 52 which when the folded blank is inserted in the tray cover the bottom of the latter. Although the inherent stiffness of the structure is sufficient to hold the partitions properly in position if the folded blank 45 fits the inner tray space, additional means may be applied. E. g. the panels 52 may be glued to the tray bottom. Furthermore pins as indicated at 53 may be driven through the tray walls 44 so as to project between the doubling of the partitions.

In a similar manner a rack 66 may be provided along a side Wall 6| of a fabric lined box 62 of which in Fig. 8 only a portion of the card board structure 63 and its lining 64 are shown. In this case a piece of card board 65 of a width equal to that of the interior of the box 62 is scored at 66 and 61 and then covered by a piece of fabric 68 glued to the non-scored face of the card board The one end portion of the covered card board is folded over along the scoring 61 and glued at 69 to the then adjacent portion to form a doubled wall thickness. The fabric is stitched to the board at 70 approximately where the doubling begins. The other end portion of the covered card board is riveted or stapled at 'H to the wall of 6! of the box 62. The piece 65 is then folded Z-shaped and secured to the Walls d2 of the box by pins 73 as hereinbefore described with respect to the pins 53 in Fig. 6.

Thus according to the invention structures are formed of folded card board covered by a fabric on one of its faces, the card board being scored on its fabric covered face where outer corners are formed and the fabric being stitched to the card board along the lines of inner corners.

It will be apparent to those skilled in the art the many alteration and modification of the structures illustrated and described can be made without departure from the essence and spirit of the invention which for that reason shall not be limited but by the scope of the appended claims.

I claim:

1. A method of making a structure of card board, fabric-covered on one of its faces and bent to forms at least one inside and one outside fabric-covered corner, which comprises the steps of preparing a card board blank in the form of a de- Pr ed.

' velopment of the desired structure, scoring the blank on one of its faces along a line where said outside corner is to be formed, preparing a piece of fabric somewhat larger than said blank and covering with it the scored face of said blank so that a margin of said fabric projects beyond the edges of said blank, turning said margin over said edges and gluing it to the other face of said blank, sewing said fabric to said blank with stitches along a line where said inside corner is to be formed, and folding said fabric-covered blank outwardly along said score and inwardly alon said line of stitches.

2. In a method of making a fabric-lined card board box havin inside and outside fabriccovered corners, the steps of preparing a card board blank in the form of a development of the desired box, scoring the blank on one of its faces along lines where the outsid corners are to be formed, preparing a piece of fabric somewhat larger than said blank and covering with it the scored face of said blank so that a margin of said fabric projects beyond the outer edges of said blank, turning said margin over said edges and gluing it to the other face of said blank, sewing said fabric to said blank with stitches alon lines where said inside corners are to be formed, and folding said fabric-covered blank outwardly along said scores and inwardly along said lines of stitches.

3. A method of making a series of partitions of a fabric-lined rectangular box-like structure which comprises preparing a rectangular card board blank, the one pair of opposite sides of said blank being equal in length to the one pair of opposite sides of the box interior, the other pair of sides of said blank being equal in length to the other pair of sides of the box interior plus twice the sum of the heights of the desired partitions, scoring the blank on its one face along lines parallel to its first mentioned sides, a first one of said scores being at a distance from the adjacent parallel side of the blank equal to the desired distance of the desired partition adjacent said side plus the desired height of said partition, each two adjacent scores being at a distance from one another equal to the desired spacing of two adjacent partitions plus the sum of the heights of said partitions, preparing a rectangular sheet of fabric somewhat larger than said blank and covering with it the scored face of said blank so that a margin of said fabric projects beyond the edges of said blank, turning said margin over said edges and gluin it to the other face of said blank, sewing said fabric to said blank with lines of stitches parallel to and on both sides of each of said scores at distances therefrom equal to the desired height of a partition, folding the blank outwardly along the scores and inwardly along the lines of stitches, and securing the so-formed panels adjacent each score fiat to one another thereby forming partitions of fabric-covered doubled card board when the so obtained structure is inserted into said box.

4. A process of making a fabric-lined box-like structure comprising the steps of preparing a rectangular frame supported by corner uprights, preparing a cardboard blank including a center portion of a size and form according to the clear space of said frame, and also including side portions extending from the sides of said center portion somewhat in excess of the desired inner depth of said box, scoring said blanks on one of its faces along lines spaced from said center portion a distance equal to said desired depth, preparing a substantially rectangular piece of fabric of a size somewhat larger in both dimensions than the maximum length and width of said blank and placing it on the scored face of the blank, turning the over-hanging margins of the fabric over the outer edges of the scored blank portions and gluing the turned-over margins to the other face of said blank, sewing said fabric to said blank in lines of stitches between the center portion and the side portions of said blank, turning the side portions along said lines of stitches upwards with respect to said center portion, turning said excess of said side portions along said scores at right angles outwards, to form flanges, insert the so obtained structure in said frame, securing aid flanges to the top of said frame, and tucking the loose fabric portions at the corners formed by adjacent side portions of the blank into the space between said frame and said uprights on the outside of said cardboard structure.

5. A box comprising a skeleton including a rectangular bottom plate, a rectangular top frame and uprights secured between said bottom plate and frame, a one piece cardboard structure including a rectangular bottom panel, four upright side panels adjoining the sides respectively of said bottom panel, and outwardly directed flanges of said side panels respectively, said cardboard structure being scored along the corners between said side panels and said flanges, a rectangular piece of fabric, lining said cardboard structure and being sewed thereto along the corners between said bottom panel and said side panels, the middle portions of margins along the sides of the fabric rectangle being turned over the outer edges of said flanges and glued to the lower faces of said flanges, said card board structure being inserted in said skeleton, said flanges bearing on and being secured to said frame with said glued fabric margin therebetween, each of the corners of said piece of fabric projecting outwards of said cardboard structure between two adjacent side panels and being tucked into the space between said frame and said uprights, and a means covering said skeleton on the outside at lea-st between said bottom plate and said frame.

6. A box as claimed in claim 5, two opposite side panels of said cardboard structure including each a ledge for a tray, each ledge including two vertically spaced horizontally projecting portions of the side panel provided with said ledge, and a vertical portion connecting the ends of said projecting portions so as to form a hollow space of substantially rectangular cross-section between said projecting and connecting portions, said card board structure being scored along the corners between said connecting portion and said projecting portions, said piece of fabric covering said projecting and connecting portions on the inside of said structure, and being sewed to said cardboard in the corners between said side wall portion and said projecting portions, and a reenforcing member in said space between said projecting and connecting portions.

7. A box as claimed in claim 5, further comprising a rack within said box, said rack comprising another piece of cardboard folded in the form of a lying Z, another piece of fabric covering said other piece of cardboard, said other piece of cardboard being scored along the outside corner between the downwardly directed flange and the web of said lying 2, said other piece of fabric being sewed to said other piece of cardboard in the inside corner between the other flange and said web of said 2, and said rack being secured with said first mentioned flange to a side wall panel of said cardboard structure.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 689,678 Lane Dec. 24, 1901 1,482,727 Borchers Feb. 5, 1924 2,297,097 Best Sept. 29, 1942 

